ML100 - Polishing Test in Curved Tubes

The following test was requested by a customer who needed to polish metal curved tubes. This customer is a manufacture of metal components for a whole range of industries: automotive, medical devices, aerospace, telecommunications, energy.

This particular test was for medical devices with curved round tubes.

Curved tubes with scotch brite polishing:

curved pipe before polishing
The tube before the polishing process had some rust and dirtiness all around the surface. The customer wanted to remove it and some give a shine effect on the surface. He didn't need mirror polishing, just a brighter effect.
Giving this, it was decided to start the tests with a medium scotch brite since the surface didn't had a lot of scratches neither big imperfections to be removed.

pipe polishing

The ML100 was able to work with this curves and make the polishing effect requested by the customer. 

Please check the video of the polishing process to see the difference before and after the scotch belt:

If you have any doubt please contact us to: marketing@nsmaquinas.pt
Or visit our webpage: www.nsmaquinas.com


MLW100 6Z AT: Automatic Multiple Station Tube Polishing Machine

NS Máquinas has just developed a flexible 6 stations automatic tube finishing machine which counts with upgraded loading and unloading systems.

MLW100 6Z AT wet tube polishing machine benefits from the ML Planetary System. This system, already present in all NS Máquinas ML tube polishing solutions, consists in 2 abrasive belts which rotate around the tube while the tube is passing through the finishing heads. Since the tube is not rotating, as it happens with other tube finishing systems, the vibration is minimum. This is especially an advantage when we consider long tubes (6 or 12 meters) or large diameters. Although the standard machine is offered up to Ø114mm, NS Máquinas has models which finish tubes up to Ø310mm. 

The automatic loading and unloading systems developed turns the complete process independent from the operator. From the moment the tubes are placed on the loading table, all the tube transport is carried automatically. The tube is inserted into the planetary finishing heads by a set of rubber rollers and travels through the 6 stations.

The abrasive belts are actuated, station after station, by the signal of sensors. After the last station the tubes are again handled by rubber clamping rollers which bring the tubes to an unloading station where these are kept separated from each other, avoiding any type of minor scratch. In this way a perfect final finishing is assured. One inspection area can also be supplied at the end of the unloading table.

Different number of stations can be supplied. A 6 stations tube polishing machine design enables to remove imperfections from tube surface and to deliver a very fine roughness which can even be below 0.1 Ra. Such high level of fine surface can be suitable either for stainless steel tube polishing or in case of steel and brass polishing, when a further final coating is applied, such as chrome plating. Also in this application, removing every little imperfection might be crucial to guarantee that no minor defect will be visible after the plating process.

Nevertheless, set-ups with a lower number of stations are also available in order to meet different application requirements.

MLW100 6Z AT automatic tube polishing machine can finish tubes from 360mm long up to 6m. More, tubes with different lengths can be polished in the same batch.

Despite the main application for these tube finishing machines being round tubes and pipes finishing, due to the ML Planetary System’s flexibility, different shapes can be finished by request. Oval tubes, D shaped profiles, threaded rods, slotted or drilled tubes can be processed, keeping the quality and maintaining the reduced vibration which this system provides. A demonstration video with these functions is available HERE.

The MLW100 6Z AT automatic tube polishing machine features a water cooling system. This automatic filtration and pumping system cools down the temperature of the tube. This is particularly significant as the number of finishing stations rises. Also, this equipment dispenses dust filtration systems as the water is directed to every finishing station and is continuously keeping these areas clean. Especially when processing potentially explosive metal dust, this system is a safe, simple and reliable solution. This equipment is incorporated on the machine body and easily slides out for paper filter replacement and cleaning. Warning messages are displayed on the machine touchscreen any time the water is going lower than a minimum level or the paper filter is over.

High safety standards were applied to this polishing machine. Multiple safety devices were incorporated in order to guarantee operator’s safety all around the machine. Sensors were installed around the active areas of the machine and physical barriers on moving elements. Laser safety fences, warning sounds and lights were also applied.

MLW100 6Z AT automatic tube polishing machine counts with a powerful mobile touchscreen control where the main functions can be actuated. Choosing the stations which will do a certain job, fine adjusting each abrasive belt speed and combining with a selected tube transport speed can be done from this control unit and, more, can be saved into programs for future use. Tube diameter for the feeding and loading systems is automatically adjusted from this mobile unit.

Staged finishing is also possible to perform with this same control. Selecting only certain areas of the tube to be finished and defining which stations will perform it can be easily programed and stored on the provided control system.

The software enables to start automatic finishing stations washing when the machine is not operating. Also, it includes Energy Saving System which will switch off the finishing heads whenever a tube is not being processed. This feature is a good help in keeping a reduced consumption of wear parts, as a more efficient use of bearings, v-belts and rubber rollers is now possible to achieve.

MLW100 6Z AT tube polishing machine is an automatic solution for high quality tube finishing which provides a completely autonomous operation from the operator. Being capable of processing not only round tubes, but also some irregular profiles, this machine brings therefore huge advantages to the tube finishing and polishing applications.
If you have any doubt please contact us to: marketing@nsmaquinas.pt
Or visit our webpage: www.nsmaquinas.com


OD120: Tube End Deburring and Edge Rounding

Round tube end with burrs and sharp edges
Burrs are projections of material beyond the workpiece limits. It consists of an undesirable extended surface over the piece. The burr formation is almost impossible to avoid due to manufacturing processes, formation mechanisms, shape and material properties. On the other hand, there are several deburring processes to remove efficiently the burrs from a different variety of geometries. 

Manual deburring process
The usual and oldest process consists in manually remove the burrs by using an abrasive or wire brush deburring tool. This method is widely used because of its extreme flexibility, low cost and lack of technology needed. On the other hand, this process is time consumable which reduces the productivity and, consequently, increases the waste time and delay in the production lines. Also, there are some disadvantages of the manual process: brush wires may be unleash; the operator can lose control of the tube and, since the operator is more exposed to the brush and the cutting edges of the tube, may suffer hands injuries.

OD120 Tube End Deburring Machine
OD Tube End Deburring Machine is one the most efficient solution to remove the burrs, clean and remove tube sharp edges from different cutting processes such as sawing. This machine enables simultaneous outside and inside tube burrs removal without rotating the tube. The solution to deburr tube ends with OD Tube End Deburring Machine is the answer to the manual process with a productive, safer, simpler and flexible deburring method.

NS Máquinas is currently working with a company which needs enhance its deburring process by removing all the burrs from round tubes to be used in opening/closing systems for buses. 
The company produces components and systems for the pneumatic control of transport vehicles such as buses and other public vehicles with pneumatic door systems. In order to ensures the door kinematics, the system uses a tube fixed to the pneumatic device which will guide the door when it is opening or closing. 
This tube needs, most of the time, to be curved and, in order to bend the tube, it needs to be deburred first for mandrel. 
Also, the company has available handrails for the doors which are curved and needs to be completely straight and without burrs on the tube end in order to be fixed on the walls or on the door itself.
Round tube end deburring and edge rounding

OD120 Brush Protection and Fast Tube Clamping System
The operation is very simple because the operator doesn't need to rotate the tube as the brushes rotate all around the shape. Also, due to its fast tube clamping system the OD Tube End Deburring Machine is capable to deburr and easily operate different shapes – from round to square tubes and aluminum profiles - treating all edges uniformly. This system was developed not only to fix the tube while doing the deburring process but also to cover the brush and avoid injuries for the operator as well as ensure a cleaner environment.

The result is a machine with the extreme flexibility of the manual process and more importantly is a safer and faster way to remove the burrs from the tubes end.

For more information, please visit our website and the OD120 webpage. Also you can contact us through our email: marketing@nsmaquinas.com.